Displaying items by tag: France
Update on calcined clays in Europe, February 2023
15 February 2023Congratulations to Lafarge France for launching the first calcined clay cement unit in Europe. The subsidiary of Holcim says that the unit, based at the integrated Saint-Pierre-la-Cour cement plant, is the first of its kind on the continent. It is using the company’s proprietary proximA Tech technology and will produce up to 500,000t/yr of cement in its ECOPlanet range. The operation is also powered with biomass alternative fuels and uses a waste recovery system to further drive down overall CO2 emissions. Once production ramps-up the producer expects that 30% of cement from the Saint-Pierre-la-Cour plant will be from the ECOPlanet range by 2024.
The investment at Saint-Pierre-la-Cour was Euro40m. Holcim is also producing calcined clay cement at its La Malle plant in France. It received an investment of Euro6m in 2022 to produce low-carbon cements. Together, both plants are aiming to produce over 2Mt/yr of calcined clay cement by 2024. As is usual for these kinds of projects, the French government partly funded the clay calcination unit at Saint-Pierre-la-Cour as part of the ‘France Relance’ scheme investing in large-scale decarbonisation and energy efficiency initiatives.
Calcined clay cements in Europe aren’t exactly new, but Holcim’s new unit in France does appear to be the first full-scale line located at a cement plant. Research by OneStone Consulting, for example, reckons that the first flash activated clay unit expressly set up to supply the cement sector was commissioned in 1995 in Toulouse, France. More recently, Hoffmann Green Cement inaugurated its 50,000t/yr pilot plant at Bournezeau in France in 2018. This site produces cements made from flash calcined clay and blast furnace slag, although it is unclear how demand for the different products varies. A new 0.25Mt/yr plant in the Vendée department was scheduled for commissioning in the second half of 2022. Another 0.25Mt/yr plant in Dunkirk is expected to be commissioned in the second half of 2024.
Cementir Group launched its calcined clay cement product FUTURECEM in Denmark in 2021 with production via a pilot plant. It then extended this to the Benelux and French cement markets in 2022. As part of its industrial plan for 2021 - 2023 it was planning to build a clay calcination unit to support the growth of FutureCem. FLSmidth revealed in June 2021 that it had won a contract to build a 400t/day clay calcination unit for Vicat’s Xeuilley integrated cement plant. The deal was worth around Euro27m and commissioning is scheduled for 2023.
Firstly, it is interesting to see a focus on France for some of the projects above. The presence of Lafarge’s technical centre in Lyon may explain the interest for that company. However, Hoffmann Green Cement and Vicat are also active in the field. It is worth noting that France also holds a busy secondary cementitious material market with standalone operators including Ecocem, Cem’In’Eu and Hoffmann Green Cement. Secondly, despite the early start, clay calcination for cement is currently more active outside of Europe. In Africa, for example, there is at least one live full production line and a number of other projects on the way. Various other pilots and projects are also happening elsewhere around the world, often in conjunction with the limestone calcined clay cement (LC3) initiative. Where calcined clay cement production in Europe goes from here is uncertain at present as it is one solution among many for lower carbon cement products in the future. Yet, the projects that have made it so far to the commercial scale will be watched closely by the companies that have invested in them - and their competitors.
Rising Vicat sales fail to stop earnings slide
15 February 2023France: Vicat’s full year results for 2022 show a 16.6% year-on-year rise in consolidated sales, from Euro3.12bn to Euro3.12bn. Its earnings before interest, tax, depreciation and amortisation (EBIDTA) came to Euro570m, a 7.9% fall compared to Euro619m in 2021. Its net income for 2022 was Euro156m, a fall of 23.6% year-on-year from Euro204m in 2021.
Commenting on these figures, Guy Sidos, the Group’s chair and chief executive officer, said “In 2022, the Vicat Group demonstrated resilience amid tough conditions. Faced with an unfavourable basis of comparison as a result of the sharp post-Covid rebound in business trends during 2021, a very strong increase in energy costs and non-recurring industrial costs in the US, France and India, we responded rapidly, raising our selling prices significantly across almost all the markets in which we operate to offset the impact of inflation. We have made progress with our policy of lowering our greenhouse gas emissions by harnessing existing solutions and investing in technologies that will enable us to reach our new 2030 targets.”
Holcim opens its first calcined clay unit in Saint-Pierre-la-Cour cement plant in France
13 February 2023France: Holcim has opened what it says is the first calcined clay unit in Europe at its Saint-Pierre-la-Cour cement plant. The production line uses the company’s proximA Tech process to produce up to 0.5Mt/yr of products in the ECOPlanet range. The unit is powered with 100% biomass-based alternative fuels and uses waste heat recovery systems to make production “nearly carbon free and ultra-efficient.”
Miljan Gutovic, Region Head Europe for Holcim, said “The opening of the first calcined clay cement production line in Europe is another milestone in our mission to decarbonise building. We are scaling up our calcined clay cements across all regions by 2025, to advance our ECOPlanet range of low-carbon cement, making low-carbon construction possible at scale.”
The upgrade project received financial support from the French government, as part of the ‘France Relance’ scheme to invest in large-scale decarbonisation and energy efficiency initiatives.
Image by Simon de l'Ouest CC BY-SA 4.0
Update on construction and demolition waste, February 2023
01 February 2023Cemex launched a new waste management division called Regenera this week. Cemex describes Regenera as a “business that provides circularity solutions, including reception, management, recycling, and coprocessing of waste.” The Mexico-based company has a long and leading history with sourcing and using alternative fuels in the cement sector and the new organisation looks set to utilise this experience. What is notable though is how the business is targeting three waste streams: municipal and industrial; industrial by-products; and construction, demolition and excavation waste (CDEW). Bringing the three waste streams together in this way appears to be novel for the heavy building materials sector, particularly the inclusion of CDEW, which we will explore further here.
CDEW is split into fractions, just like the municipal and solid waste streams that end up as alternative fuels at cement plants, but the biggest fractions are generally concrete, followed by bricks. The recycled concrete is then typically used as an aggregate, either in new concrete production or in areas like road construction and earthworks. The use of recycled aggregates (RA) made from CDEW goes back to at least the 1930s in its current form although ‘reusing’ materials from structures such as castles and churches goes back far further. Recycling and reusing CDEW gained a boost in 2020 when the European Union (EU) set a 70% recovery target. However, within the EU the CDEW recycling rates vary considerably and that 2020 target includes the use of CDEW in backfill applications.
In its launch statement for Regenera, Cemex noted that it operates a dock in Paris, where it receives a variety of materials, including construction debris, excavated material and inert soil. These materials are sorted, processed and then transformed into recycled aggregates or organic material used to restore quarries. Cemex then promptly followed up the official launch of Regenera on 30 January 2023 with the acquisition of a majority stake in Shtang Recycle, an Israel-based CDEW recycling company. It added that Shtang Recycle is preparing to build a recycling plant with a production capacity of 0.6Mt/yr of CDEW waste materials. The output from the plant will be used as raw materials for aggregate production.
The focus on CDEW recycling was flagged up at Cemex’s investor event in November 2022. It said that it was targeting a recycling rate of 14Mt/yr of construction and demolition waste by 2030. Other managed waste stream goals included doubling the amount of municipal and industrial waste it manages, to achieve a 50% to fossil fuel substitution rate, and increasing its usage of alternative raw materials and by-products by 30%, thereby eliminating 13Mt/yr of extracted materials.
Cemex is not alone in targeting the CDEW waste sector. Holcim’s recent work in the area goes back to at least 2016 when a recycling unit near its Retznei cement plant in Austria started processing 130,000t/yr of CDEW. It announced in December 2022 that it was setting up a similar recycling centre, also in Austria, at its Mannersdorf cement plant. In October 2022 Holcim acquired Wiltshire Heavy Building Materials in the UK. This company recycles 150,000t/yr of construction and demolition waste into aggregates and concrete. Holcim linked the acquisition to its Strategy 25 target of recycling 10Mt/yr of construction and demolition waste by 2025.
Activity by other cement companies includes the commissioning of a construction waste recycling plant at Gennevilliers in France by CRH-subsidiary Eqiom in April 2022. It was aiming for a target of 50,000t in 2022. In November 2022 Heidelberg Materials agreed to acquire RWG Holding based in Berlin, Germany. Then, in December 2022, it announced a deal to buy Mick George Group in the UK. Both proposed acquisitions are subject to competition authority approval. Heidelberg Materials’ current target is to offer circular alternatives for half of its concrete products by 2030.
The moves by the bigger cement companies into the CDEW sector follow sustainable thinking and the waste hierarchy. Yet the big prize here is to gain a route to dispose of some of their CO2 emissions through recarbonation and this has been flagged up in several net-zero roadmaps for the cement sector such as those by Cembureau and the Global Cement and Concrete Association (GCCA). Holcim has been involved in the FastCarb project in France, running a pilot at its Val d’Azergues cement plant in 2021. Heidelberg Materials has been testing its own process with so-called recycled concrete paste. The development now appears to be that utilising CDEW has entered the sustainability strategies for some of the big cement-concrete-aggregate producers, targets have been set and acquisitions are happening.
For more information on Heidelberg Materials research into concrete recycling read the January 2023 issue of Global Cement Magazine
Platinum Equity completes acquisition of Calderys
01 February 2023France: Private equity investment company Platinum Equity has completed its acquisition of Calderys from Imerys. It announced in July 2022 that it had agreed to pay around Euro930m to buy Imerys’ High Temperature Solutions business (HTS). Michel Cornelissen will remain as the president and chief executive officer of the refractory manufacturer.
In December 2022 Platinum Equity said that it has signed a definitive merger agreement to buy HarbisonWalker International (HWI), a supplier of refractory products and services in North America. the move is intended to create a global refractories supplier. The HWI deal is expected to complete in the first half of 2023 subject to closing conditions and regulatory approval.
Holcim acquires Chrono Chape
05 January 2023France: Switzerland-based Holcim has acquired self-levelling screed producer Chrono Chape. Chrono Chape’s screeds create even foundations for builders to lay floors on. It serves its customers in France with a fleet of batching trucks.
Holcim’s Europe region head Miljan Gutovic said “I am excited to acquire Chrono Chape, as another step in advancing our Strategy 2025 – Accelerating Green Growth. With this operation, we will expand our range of services and geographic footprint in France. Building on the entrepreneurial vision and legacy of the Dupuy family, I look forward to investing in this business’ next era of growth and warmly welcoming their employees into the Holcim family.”
N + P Group's planned Isbergues Subcoal plant receives clearance
25 November 2022France: Authorities have granted construction and environmental clearances to N + P Group to set up its planned Isbergues Subcoal solid recovered fuel (SRF) plant in Hauts-de-France. When commissioned in 2024, the 150,000t/yr-capacity plant will be France's first to commercially produce the coal alternative for cement and other industries. The company says that its products will be able to eliminate 100,000t/yr of industrial CO2 emissions nationally. N + P Group will use locally sourced waste at the unit.
Chief development officer Lars Jennissen said “Obtaining the environmental and construction permit is a major achievement for us, and we thank our colleagues and partners for their hard work in realising this important milestone. The new location will contribute to the circular economy in Hauts-de-France by converting regional non-recyclable wastes into new resources for regional customers, and it offers a massive potential CO2 savings for the French market.”
France: Ecocem has appointed Christian Clergue as its European Standardisation Manager. He started his career in the late 1980s working for Vicat, according to AC Presse. During his time with the group he led its SigmaBeton engineering subsidiary and worked as a project manager in fibre concrete and high performance materials. He later worked as a research and development director for Serge Ferrari and then as a department director for Eiffage Genie Civil.
Holcim to delist from Euronext Paris
21 November 2022France/Switzerland: Holcim plans to delist all shares from the Euronext Paris exchange. Shares in the Switzerland-based group will continue to trade on the SIX Swiss Exchange. The cement producer explained its decision in terms of its need to simplify its trading structure. It expects thereby to further reduce its administrative costs and requirements.
Vicat revenues rise against uncertain backdrop
08 November 2022France: Vicat’s revenue in the first nine months of 2022 came to Euro2.70bn, a 15% rise year-on-year compared to Euro2.35bn in the same period in 2021. Its revenues in France rose by 8% to Euro889m from Euro824m. Its revenue in the rest of Europe fell by 4.5% to Euro288m from Euro301m. In the Americas, Vicat’s revenues increased by 27% to Euro637m from Euro500m, while they rose even more dramatically across the Mediterranean rim, up by 57% from Euro166m to Euro260m. In Africa revenues came to Euro245m, broadly unchanged on the year. In its Asia region, including Kazakhstan and India, its revenues rose by 18% to Euro376m from Euro320m.
The group’s sales volumes of cement fell by 5% to 20.3Mt from 21.3Mt. However, price rises enabled it to increase its operational revenue by 18% to Euro1.69bn from Euro1.43bn. Similarly, concrete sales volumes fell by 4.8% to 7.48Mm3 but operational sales rose by 16% to Euro1.04bn.
Guy Sidos, the group's chair and chief executive officer said "Vicat's nine-month sales performance reflects the resilience of its markets despite a high basis of comparison in 2021. Against a backdrop of very high inflation, the group's sales posted a solid increase compared with the same period of 2021, supported by strong growth in selling prices across all its regions. In a global environment that provides little short-term visibility, especially regarding energy costs, we are executing our strategy to improve our industrial performance, make greater use of secondary fuels, reduce our carbon footprint and implement a pricing policy tailored to these new conditions."
Vicat announced that it expects its overall earnings before interest, tax, depreciation and amortisation (EBITDA) to be lower in 2022 as a whole than in 2021 but comparable to 2020.